Pump plungers and methods

Abstract

Various embodiments of the invention provide pumps, plungers and plunger assemblies, as well as methods of using them. In accordance with some embodiments, a plunger may comprise a ceramic material and/or may have a facial profile that may allow for more efficient pumping operations. In particular embodiments, for example, a plunger may have a facial profile that allows for deformation of at least a portion of the plunger when the face of the plunger is in contact with a pressurized fluid. Other embodiments provide plunger assemblies, which may comprise a flexible coupling attachment. Yet other embodiments provide pumps comprising such plungers and/or plunger assemblies.

1 . A plunger assembly for use in a pump, the plunger assembly comprising: 
 a plunger having an axis, a first end portion and a second end portion, the first end portion being configured to be coupled with a flexible coupling assembly and the second end portion being configured to be exposed to a pump chamber, such that a reciprocal motion of the plunger along the axis of the plunger can result in the pumping of a fluid through the pump chamber;    a drive element having an axis, the drive element being configured for reciprocal motion along the axis of the drive element; and    a flexible coupling assembly coupled with the first end portion of the plunger and further coupled with the drive element, the flexible coupling assembly being configured to translate the reciprocal motion of the drive element to the plunger, causing a reciprocal motion of the plunger along the axis of the plunger.    
   
   
       2 . A plunger assembly as recited in  claim 1 , wherein the flexible coupling assembly comprises a length of PVC tubing.  
   
   
       3 . A plunger assembly as recited in  claim 1 , wherein the drive element is configured to be coupled with a drive mechanism capable of providing the reciprocal motion of the drive element.  
   
   
       4 . A plunger assembly as recited in  claim 1 , wherein the axis of the plunger and the axis of the drive element are generally axially aligned.  
   
   
       5 . A plunger assembly as recited in  claim 4 , wherein the flexible coupling assembly is configured to allow the axis of the plunger and the axis of the drive element to be aligned relatively imprecisely.  
   
   
       6 . A plunger assembly as recited in  claim 1 , wherein axis of the plunger and the axis of the drive element are not axially aligned, and wherein the flexible coupling assembly is configured to translate the reciprocal motion of the drive element to the plunger, causing a reciprocal motion of the plunger along the axis of the plunger, even though the respective axes of the drive element and the plunger are not axially aligned.  
   
   
       7 . A plunger assembly as recited in  claim 1 , wherein the plunger comprises a metal.  
   
   
       8 . A plunger assembly as recited in  claim 1 , wherein the plunger comprises a ceramic material.  
   
   
       9 . A plunger assembly as recited in  claim 8 , wherein the plunger comprises a material selected from the group consisting of aluminum oxide, transformation-toughened zirconia, and approximately 99.5 percent Al 2 O 3 .  
   
   
       10 . A plunger assembly as recited in  claim 1 , wherein the plunger is generally cylindrical in shape.  
   
   
       11 . A plunger assembly as recited in  claim 10 , wherein the plunger is between about one-quarter inch and about three inches in diameter.  
   
   
       12 . A plunger assembly as recited in  claim 1 , wherein the plunger is configured to be slidably disposed at least partially within a plunger housing, and wherein the second end portion has a facial profile defining an opening and is configured to be exposed to a pump chamber and in contact with a fluid, such that a reciprocal motion of the plunger with respect to the pump chamber exerts a pressure on the fluid, allowing the fluid to be pumped, such that, when the plunger is in contact with the fluid, the fluid exerts sufficient pressure on the facial profile to cause a deformation of at least part of the plunger.  
   
   
       13 . A plunger for use in a pump, the plunger comprising a first portion configured to be slidably disposed at least partially within a plunger housing and a second portion having a facial profile defining an opening, the second portion being configured to be exposed to a pump chamber and in contact with a fluid, such that a reciprocal motion of the plunger with respect to the pump chamber exerts a pressure on the fluid, allowing the fluid to be pumped, wherein, when the plunger is in contact with the fluid, the fluid exerts sufficient pressure on the facial profile to cause a deformation of the second portion of the plunger.  
   
   
       14 . A plunger as recited in  claim 13 , wherein the plunger has an exterior diameter configured to fit an interior diameter of the plunger housing to within a certain tolerance when no pressure is applied to the facial profile, such that when the fluid exerts sufficient pressure on the facial profile to cause a deformation of the second portion of the plunger, the deformation reduces the certain tolerance.  
   
   
       15 . A plunger as recited in  claim 13 , wherein the sufficient pressure exerted on the facial profile to cause a deformation of the second portion of the plunger is between about 500 pounds per square inch and about 6000 pounds per square inch.  
   
   
       16 . A plunger as recited in  claim 13 , wherein the reciprocal motion of the plunger results in a certain amount of leakage of the fluid along the length of the plunger, and wherein the deformation of the second portion of the plunger functions to reduce the certain amount of leakage.  
   
   
       17 . A plunger as recited in  claim 13 , wherein the plunger comprises a metal.  
   
   
       18 . A plunger as recited in  claim 13 , wherein the plunger comprises a ceramic material.  
   
   
       19 . A plunger as recited in  claim 18 , wherein the plunger comprises a material selected from the group consisting of aluminum oxide, transformation-toughened zirconia, and approximately 99.5 percent Al 2 O 3 .  
   
   
       20 . A plunger as recited in  claim 13 , wherein the plunger is generally cylindrical in shape.  
   
   
       21 . A plunger as recited in  claim 13 , wherein the facial profile defines an opening that is generally cylindrical in shape.  
   
   
       22 . A plunger as recited in  claim 21 , wherein a ratio of a cross-sectional diameter of the opening defined by the facial profile to a cross-sectional diameter of the plunger is between about 0.3 and about 1.0.  
   
   
       23 . A plunger as recited in  claim 21 , wherein the facial profile defines an opening with a cross-section that is between about one-eighth inch and about three inches in diameter.  
   
   
       24 . A plunger as recited in  claim 21 , wherein the facial profile defines an opening that is between about three-eighths inch and about one-and-one-quarter inch in length.  
   
   
       25 . A plunger as recited in  claim 13 , wherein the facial profile defines an opening that is roughly hemispherical in shape.  
   
   
       26 . A plunger as recited in  claim 25 , wherein the facial profile defines an opening with a diameter approximately equal to a cross-sectional diameter of the plunger.  
   
   
       27 . A plunger as recited in  claim 25 , wherein ratio of a diameter of the opening defined by the facial profile to a cross-sectional diameter of the plunger is between about 0.3 and about 1.0.  
   
   
       28 . A plunger as recited in  claim 13 , wherein the facial profile defines an opening with a keyhole shape.  
   
   
       29 . A plunger as recited in  claim 13 , wherein the facial profile defines a channel in a face of the plunger.  
   
   
       30 . A plunger as recited in  claim 29 , wherein a length of the channel spans a cross-sectional diameter of the plunger.  
   
   
       31 . A plunger as recited in  claim 29 , wherein a width of the channel is about one-quarter to about three-quarters of a cross-sectional diameter of the plunger.  
   
   
       32 . A plunger as recited in  claim 13 , wherein the plunger is configured to be coupled with a flexible coupling assembly.  
   
   
       33 . A method of using a plunger to pump fluids, the method comprising: 
 providing a plunger having an axis, a first portion and a second portion, the first portion being configured to be coupled with a drive element and the second portion being configured to be exposed to a pump chamber, such that a reciprocal motion of the plunger along the axis of the plunger can result in the pumping of a fluid through the pump chamber;    providing a drive element having an axis, the drive element being configured for reciprocal motion along the axis of the drive element;    coupling the drive element with the first portion of the plunger using a flexible coupling assembly, the flexible coupling assembly being configured to translate the reciprocal motion of the drive element to the plunger, causing a reciprocal motion of the plunger along the axis of the plunger; and    imparting a reciprocal motion to axis of the drive element, thereby causing the plunger to move in a reciprocal motion along the axis of the plunger.    
   
   
       34 . A method of using a plunger to pump fluids as recited in  claim 33 , wherein the plunger is configured to be slidably disposed at least partially within a plunger housing, and wherein the second portion has a facial profile defining an opening and is configured to be exposed to a pump chamber and in contact with a fluid, the method further comprising: 
 exerting sufficient pressure on the facial profile of the plunger to cause a deformation of at least part of the plunger.    
   
   
       35 . A method of using a plunger to pump fluids as recited in  claim 34 , wherein the plunger has an exterior diameter configured to fit an interior diameter of the plunger housing to within a certain tolerance when no pressure is applied to the facial profile, such that when sufficient pressure is exerted on the facial profile to cause a deformation of at least part of the plunger, the deformation reduces the certain tolerance.  
   
   
       36 . A method of using a plunger to pump fluids as recited in  claim 35 , wherein the reciprocal motion of the plunger results in a certain amount of leakage of the fluid along the length of the plunger, and wherein the deformation of the second portion of the plunger functions to reduce the certain amount of leakage.  
   
   
       37 . A method of using a plunger to pump fluids as recited in  claim 33 , wherein the plunger comprises a metal.  
   
   
       38 . A method of using a plunger to pump fluids as recited in  claim 33 , wherein the plunger comprises a ceramic material.  
   
   
       39 . A method of using a plunger to pump fluids, the method comprising: 
 providing a plunger comprising a first portion configured to be slidably disposed at least partially within a plunger housing and a second portion having a facial profile defining an opening, the second portion being configured to be exposed to a pump chamber and in contact with a fluid, such that a reciprocal motion of the plunger with respect to the pump chamber can exert pressure on the fluid, allowing the fluid to be pumped, wherein, when the plunger is in contact with the fluid, the fluid exerts sufficient pressure on the facial profile to cause a deformation of the second portion of the plunger; and    moving the plunger in a reciprocal motion along the axis of the plunger.    
   
   
       40 . A method of using a plunger to pump fluids, as recited in  claim 39 , wherein the plunger has an exterior diameter configured to fit an interior diameter of the plunger housing to within a certain tolerance when no pressure is applied to the facial profile, such that when the fluid exerts sufficient pressure on the facial profile to cause a deformation of the second portion of the plunger, the deformation reduces the certain tolerance.  
   
   
       41 . A method of using a plunger to pump fluids, as recited in  claim 39 , wherein the sufficient pressure exerted on the facial profile to cause a deformation of the second portion of the plunger is between about 500 pounds per square inch and about 6000 pounds per square inch.  
   
   
       42 . A method of using a plunger to pump fluids, as recited in  claim 39 , wherein the reciprocal motion of the plunger results in a certain amount of leakage of the fluid along the length of the plunger, and wherein the deformation of the second portion of the plunger functions to reduce the certain amount of leakage.  
   
   
       43 . A method of using a plunger to pump fluids, as recited in  claim 39 , wherein the plunger comprises a metal.  
   
   
       44 . A method of using a plunger to pump fluids, as recited in  claim 39 , wherein the plunger comprises a ceramic material.  
   
   
       45 . A plunger pump assembly, comprising: 
 a pump body defining a pump chamber with an inlet port and an outlet port, wherein the pump body further defines a plunger port disposed between the inlet port and the outlet port;    a first check valve in fluid communication with the inlet port of the pump chamber, wherein the first check valve is configured to allow a fluid to flow only into the pump chamber;    a second check valve in fluid communication with the outlet port of the pump chamber, wherein the second check valve is configured to allow the fluid to flow only out of the pump chamber;    a plunger housing defining a cylindrical bore having an interior diameter, wherein the plunger housing is disposed within the plunger port; and    a plunger having an exterior diameter and comprising a portion with a facial profile defining an opening, wherein the plunger is slidably disposed within the cylindrical bore such that when the plunger is reciprocated back and forth within the bore, the fluid is moved from the inlet port of the pump chamber to the outlet port of the pump chamber, and wherein when the facial profile of the plunger is in contact with the fluid, the fluid exerts sufficient pressure on the facial profile to cause a deformation of at least part of the plunger.    
   
   
       46 . The plunger pump assembly of  claim 45 , wherein the plunger is coupled with a flexible coupling assembly, the flexible coupling assembly being further coupled with a drive system, such that the drive system may impart, via the flexible coupling assembly, reciprocating force on the plunger sufficient to reciprocate the plunger back and forth within the bore.  
   
   
       47 . The plunger pump assembly of  claim 46 , wherein the flexible coupling assembly comprises PVC tubing.  
   
   
       48 . The plunger pump assembly of  claim 45 , wherein the exterior diameter of the ceramic plunger fits the interior diameter of the bore to within a certain tolerance when no pressure is exerted on the facial profile of the plunger.  
   
   
       49 . The plunger pump assembly of  claim 48 , wherein the deformation of at least part of the plunger is sufficient to reduce the certain tolerance.  
   
   
       50 . The plunger pump assembly of  claim 48 , wherein the certain tolerance is in the range from about 1.0 microns to about 6.0 microns.  
   
   
       51 . The plunger pump assembly of  claim 45 , wherein at least one of the plunger and the plunger housing comprises a ceramic material.  
   
   
       52 . The plunger pump assembly of  claim 51 , wherein at least one of the plunger and the plunger housing comprises a material selected from the group consisting of aluminum oxide, transformation-toughened zirconia, and approximately 99.5 percent Al 2 O 3 .  
   
   
       53 . The plunger pump assembly of  claim 45 , wherein a surface of the plunger defines at least one discontinuity, and wherein the discontinuity is configured to reduce the escape of the fluid through the bore.  
   
   
       54 . A fluid injection system, comprising: 
 a drive system configured to impart a generally reciprocal force on a plunger; and    a plunger pump assembly, wherein the plunger pump assembly comprises: 
 a pump body defining a pump chamber with an inlet port and an outlet port, wherein the pump body further defines a plunger port disposed between the inlet port and the outlet port;  
 a first check valve in fluid communication with the inlet port of the pump chamber, wherein the first check valve is configured to allow a fluid to flow only into the pump chamber;  
 a second check valve in fluid communication with the outlet port of the pump chamber, wherein the second check valve is configured to allow the fluid to flow only out of the pump chamber;  
 a plunger housing defining a cylindrical bore having an interior diameter, wherein the plunger housing is disposed within the plunger port; and  
 a plunger having an exterior diameter and comprising a portion with a facial profile defining an opening, wherein the plunger is slidably disposed within the cylindrical bore and coupled with the drive system, such that when the plunger is reciprocated back and forth within the bore, the fluid is moved from the inlet port of the pump chamber to the outlet port of the pump chamber, and wherein when the facial profile of the plunger is in contact with the fluid, the fluid exerts sufficient pressure on the facial profile to cause a deformation of at least part of the plunger.  
   
   
   
       55 . The fluid injection system of  claim 54 , wherein the plunger is coupled with a flexible coupling assembly, the flexible coupling assembly being further coupled with the drive system, such that the drive system may impart, via the flexible coupling assembly, reciprocating force on the plunger sufficient to reciprocate the plunger back and forth within the bore.  
   
   
       56 . The fluid injection system of  claim 55 , wherein the flexible coupling assembly comprises PVC tubing.  
   
   
       57 . The fluid injection system of  claim 54 , wherein the drive system comprises a diaphragm motor dynamically coupled with the plunger and configured to reciprocally slide the plunger back and forth in the bore, thereby moving fluid from the inlet port of the pump chamber to the outlet port of the pump chamber.  
   
   
       58 . The fluid injection system of  claim 54 , further comprising a fluid source in fluid communication with the first check valve and operable to supply a fluid to the inlet port.  
   
   
       59 . The fluid injection system of  claim 57 , wherein the diaphragm motor comprises a diaphragm and a linkage, wherein the linkage is coupled with the diaphragm and further with the plunger, wherein the fluid source is a first fluid source, the system further comprising a second fluid source in fluid communication with the diaphragm motor and operable to supply a pressurized second fluid to the diaphragm motor, and wherein the diaphragm motor is configured to reciprocally slide the plunger back and forth in the bore in response to a fluid pressure imposed on the diaphragm by the second fluid.  
   
   
       60 . The fluid injection system of  claim 54 , wherein at least one of the plunger and the plunger housing comprises a ceramic material.